Mitsubishi Montero (1998+). Manual - part 57

         POWER BRAKE BOOSTER

         System Check

         1) Run engine for 1-2 minutes. Shut engine off, and depress

brake pedal several times with normal pressure. If pedal height

gradually becomes higher with successive applications, power brake

booster is okay. If pedal height remains steady, power brake booster

is not operating properly, go to next step.

         2) With engine stopped, depress brake pedal repeatedly until

pedal height no longer falls. Hold brake pedal down, and start engine.

If pedal moves downward slightly, power brake booster is okay. If

pedal height does not change, power brake booster is not operating

properly, go to next step.

         3) With engine running, press and hold brake pedal. Shut off

engine. Hold brake pedal for 30 seconds. Brake pedal height should not

change. If pedal rises, power brake booster is not operating properly,

go to next step.

         4) If brake booster operation is not as specified in each

step, disconnect vacuum hose at brake booster and check for sufficient

vacuum with engine running. Also check brake booster check valve

operation. Repair or replace as necessary.

         Check Valve Inspection

         Remove vacuum hose from power brake booster. Do not remove

check valve from hose. Check valve should hold vacuum in one direction

and allow air to pass in other direction.

         LOAD-SENSING PROPORTIONING VALVE (LSPV)

         Montero

         1) Before diagnosing Load-Sensing Proportioning Valve (LSPV),

ensure all other brake components are operating properly. When all

other brake system components are determined to be okay, ensure LSPV

spring length is within specification. See  Fig. 1. See LOAD-SENSING

PROPORTIONING VALVE (LSPV) under ADJUSTMENTS.

         2) After spring length is determined to be within

specification, connect pressure gauges to input and output ports of

LSPV. See Fig. 7. Bleed brake system. See BLEEDING BRAKE SYSTEM.

Fig. 7:  Connecting Pressure Gauges To LSPV (Montero)

Courtesy of Mitsubishi Motor Sales of America.

         3) With vehicle unloaded at correct ride height and LSPV

spring correctly adjusted to 8.9" (227 mm), slowly depress brake pedal

and check fluid input and output pressures at LSPV. See

LSPV PRESSURE SPECIFICATIONS table.

         4) Disconnect spring at support and pull spring and lever

toward support until spring length is 10.1" (257 mm). See  Fig. 1.

Slowly depress brake pedal and check input and output pressures at

LSPV. See LSPV PRESSURE SPECIFICATIONS table. If fluid input pressure

is okay and output pressure is not within specification, replace LSPV

assembly. Remove gauges and bleed brake system.

LSPV PRESSURE SPECIFICATIONS

LSPV Spring                 Inlet Pressure             Outlet Pressure

Length                        psi (kg/cm



)                psi (kg/cm



)

8.9" (227 mm)  .............  1422 (100)  ..........  873-1002 (61-70)

8.9" (227 mm)  .............  2560 (180)  .........  1129-1314 (79-92)

10.1" (257 mm)  ............  2560 (180)  .......  1863-2148 (131-151)

         NON-LOAD-SENSING PROPORTIONING VALVE

         Pressure Test (Except Montero)

         1) Connect pressure gauges to input and output ports of

proportioning valve. See Fig. 8. Bleed brake system. See

BLEEDING BRAKE SYSTEM.

Fig. 8:  Connecting Pressure Gauges To Proportioning Valve (Typical)

Courtesy of Mitsubishi Motor Sales of America.

         2) Slowly depress brake pedal. Check readings on pressure

gauges. Ensure output pressure begins to drop relative to input

pressure at specified pressure range (split point). See

SPLIT POINT PRESSURE SPECIFICATIONS table.

SPLIT POINT PRESSURE SPECIFICATIONS

Application                                               psi (kg/cm



)

Diamante   ..........................................  312-383 (22-27)

Eclipse

  Without ABS  ......................................  320-391 (22-27)

  With ABS  .........................................  320-391 (22-27)

Galant  .............................................  462-533 (33-38)

Mirage

  2-Door  ...........................................  320-392 (22-26)

  4-Door  ...........................................  391-463 (27-32)

Montero Sport  ..................................................  ( 1)

(1) - Information not available from manufacturer.

         3) Continue depressing brake pedal, and check readings on

pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS

table. If fluid pressures or split point are not within specification,

replace proportioning valve.

PROPORTIONING VALVE PRESSURE SPECIFICATIONS

Application/                Inlet Pressure         (1) Outlet Pressure

Model                         psi (kg/cm



)                psi (kg/cm



)

Diamante  ...................  1138 (80)  ...........  676-747 (48-53)

Eclipse

  With ABS  .................  996 (69)  ............  569-640 (39-44)

  Without ABS  ..............  925 (61)  ............  462-533 (32-37)

Galant  .....................  996 (69)  ...................  604 (43)

Mirage

  2-Door  ...................  1422 (98)  ...........  566-680 (39-47)

  4-Door  ...................  1422 (98)  ...........  619-733 (43-51)

3000GT

  Hatchback  ................  906 (64)  ............  651-723 (46-51)

  Convertible  ..............  1117 (79)  ...........  846-917 (60-65)

Montero Sport  .................  (1)  ..........................  (1)

(1) - Information is not available from manufacturer.

         REMOVAL & INSTALLATION

         FRONT DISC BRAKE PADS

CAUTION: DO NOT remove or contaminate special grease coating on lock

         pins.

         Removal & Installation (Except 3000GT AWD)

         1) Raise and support vehicle. Remove front wheels. Remove

lower lock pin or sleeve bolt. See Figs. 13-15. Lift caliper body

upward. Support caliper aside. Remove shims and pads from support

mounting. Remove pad clips.

         2) If installing new pads, compress piston to bottom of bore.

Install retaining clips, pads and shims. Start engine and depress

brake pedal several times to expand caliper piston. Check brake fluid

level.

         Removal & Installation (3000GT AWD)

         1) Raise and support vehicle. Remove front wheels. Remove

clip, brake pad retaining pins and spring. See  Fig. 17. Remove shims

and pads from caliper. Keep track of location of shims for reassembly.

         2) Compress caliper pistons fully in bores. Install shims on

brake pads. Install brake pads. Install spring clip, pad retaining

pins and clip. Start engine and depress brake pedal several times to

expand caliper piston. Check brake fluid level.

         FRONT BRAKE CALIPER

         Removal

         Raise and support vehicle. Remove front wheels. Remove hose

clip from brake hose mount (if equipped). Disconnect brake hose from

caliper. Remove upper and lower caliper-to-steering knuckle bolts.

Lift caliper body upward. Remove caliper.

         Installation

         To install, reverse removal procedure. Tighten bolts to

specification. See TORQUE SPECIFICATIONS. Bleed brake system. See

BLEEDING BRAKE SYSTEM.

         FRONT BRAKE ROTOR

         Removal & Installation (Except Montero & Montero Sport)

         Raise vehicle, and remove wheel(s). Remove caliper. See

FRONT BRAKE CALIPER. Slide rotor off hub. To install, reverse removal

procedure.

         Removal (Montero & Montero Sport)

         Raise and support vehicle. Remove brake caliper. See

FRONT BRAKE CALIPER. On 4WD, remove Remove bearing grease cap, snap

ring, shim, 6 bolts and drive flange from axle shaft. On 2WD remove 6

bolts and hub cover. Remove screw(s) from lock washer. Remove lock

washer. Remove lock nut using Lock Nut Wrench (MB990954). Remove hub

assembly. Place match marks on rotor and hub. Remove rotor from front

hub.

         Installation

         1) Install rotor on hub. Service wheel bearings and seals as

necessary. Install front hub assembly. Install lock nut, and tighten

it to 119 ft. lbs. (165 N.m). Loosen lock nut, and retighten it to 18

ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Install lock washer

and screw(s).

         2) On 2WD, reverse removal procedure for remaining

components. On 4WD, install drive flange, shim and snap ring. Using

feeler gauge, check axle shaft-to-hub clearance. Clearance should be

0.016-0.028" (0.41-0.71 mm). Use appropriate shim to obtain correct

clearance. Shim is located behind snap ring on end of axle shaft.

Recheck clearance if necessary. Install remaining components.

         PARKING BRAKE SHOES

         Removal & Installation (Diamante)

         1) Raise and support vehicle. Remove rear wheels. Remove rear

disc brake caliper and rotor. If rotor removal is difficult, rotate

rotor until hole in rotor is upward. Back-off brake shoe adjustment

with a flat blade screwdriver through hole in rotor.

         2) Disconnect rear speed sensor. See  Fig. 9. Remove 4 bolts

and hub. Remove screw and shoe hold-down spring. Remove shoe. To

install, reverse removal procedure. Adjust brake shoe by turning

adjuster star wheel.